CAT + Caterpillar MT865 Challenger Service Repair Manual

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Product: CHALLENGER

Model: MT865 CHALLENGER BDS

Configuration: C-12, C-15, C-16 Caterpillar Engines For AGCO Challenger BDS00001-UP (MACHINE)

Disassembly and Assembly

C-15 and C-16 Industrial Engines

Media Number -RENR2346-01 Publication Date -01/09/2002 Date Updated -30/09/2002

Air Compressor - Remove and Install

SMCS - 1803-010

Removal Procedure

1

Tools

NOTICE

Keep all parts clean from contaminants.

Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components.

To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly.

Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.

NOTICE

i02468021

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.

1. Drain the cooling system into a suitable container for storage or disposal. Refer to Disassembly and Assembly, "Cooling System Coolant - Change".

2. Loosen the purge valves, and release the air pressure in the air tank.

Illustration 1

Typical example

3. Disconnect coolant tube assembly (1) and air hose assembly (2) from the air compressor.

4. Disconnect oil tube assembly (3) from the air compressor.

g00620850

Illustration 2

Typical example

g00928842

5. Remove coolant hose assembly (4) from the air compressor.

6. Remove nuts (5) that hold the air compressor to the accessory drive.

7. Remove air compressor (6) from the engine.

Illustration 3

Typical example

8. Remove O-ring seal (7) from the air compressor.

g00929487

Note: Install Tooling (A) to the mounting flange of the air compressor. Tooling (A) will keep the drive gear stationary. The retaining nut for the drive gear can be removed.

9. Remove retaining nut (8) for the drive gear.

10. Remove the air compressor drive gear from the air compressor.

Installation Procedure

Table 2

Required Tools

Tool Part Number Part Description Qty

A 132-5451 Holding Fixture 1

NOTICE

Keep all parts clean from contaminants.

Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components.

To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly.

Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.

1. Install the air compressor drive gear onto the shaft of the air compressor.

Illustration 4 g00929487

Typical example

Note: Install Tooling (A) to the mounting flange of the air compressor. Tooling (A) will keep the drive gear stationary. The retaining nut for the drive gear can be installed.

2. Install retaining nut (8) for the drive gear. For compressors that have a straight shaft, refer to Step 3 in order to tighten nut (8) . For compressors that have a tapered shaft, refer to Step 4 in order to tighten nut (8) .

3. Tighten retaining nut (8) to a torque of 460 ± 60 N·m (339 ± 44 lb ft).

4. Tighten nut (8) to a torque of 170 ± 15 N·m (125 ± 11 lb ft). Place a driver which is slightly larger than nut (8) over nut (8) and tap the driver with a hammer. Tighten nut (8) again to a torque of 170 ± 15 N·m (125 ± 11 lb ft).

5. Install new O-ring seal (7) on the air compressor.

6. Position air compressor (6) on the engine.

Illustration 5 g00620840

Typical example

7. Install nuts (5) in order to hold the air compressor on the engine.

8. Connect coolant tube assembly (4) to the air compressor.

Illustration 6

Typical example

g00620850

9. Connect coolant tube assembly (1) to the air compressor.

10. Connect air hose assembly (2) to the air compressor.

NOTICE

To prevent water from collecting and freezing in the air compressor lines, ensure that the air compressor lines are sloping downward and away from the air compressor.

Network For SIS Licensees. Mon Feb 19 23:38:38 UTC+0530 2024

Product: CHALLENGER

Model: MT865 CHALLENGER BDS

Configuration: C-12, C-15, C-16 Caterpillar Engines For AGCO Challenger BDS00001-UP (MACHINE)

Disassembly and Assembly

C-15 and C-16 Industrial Engines

Media Number -RENR2346-01

Publication Date -01/09/2002

Alternator - Remove and Install

SMCS - 1405-010

Removal Procedure NOTICE

Keep all parts clean from contaminants.

Date Updated -30/09/2002

Contaminants may cause rapid wear and shortened component life.

1. Turn the battery disconnect switch to the OFF position.

i01810705

Illustration 1 g00596882

Illustration 2 g00596913

2. Put identification on the harness assemblies for installation purposes. Remove the harness assemblies from alternator (3).

3. Loosen nuts (5) on the adjustment rod.

4. Loosen the nut on bolt (1). Push the top of the alternator toward the cylinder block. Remove V-belt (2).

5. Remove bolts (1) and (4). Remove alternator (3).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 3 g00596882

Illustration 4 g00596913

1. Put alternator (3) in position on the alternator bracket and install bolt (1).

2. Put the adjustment rod in position on the alternator and install bolt (4).

3. Install V-belt (2). Tighten the V-belt. Refer to Testing and Adjusting, "Belt Tension Chart".

4. Tighten nuts (5) to a torque of 30 ± 15 N·m (22 ± 11 lb ft).

5. Install the harness assemblies on the alternator.

6. Turn the battery disconnect switch to the ON position.

Product: CHALLENGER

Model: MT865 CHALLENGER BDS

Configuration: C-12, C-15, C-16 Caterpillar Engines For AGCO Challenger BDS00001-UP (MACHINE)

Disassembly and Assembly

C-15 and C-16 Industrial Engines

Media Number -RENR2346-01

Publication Date -01/09/2002

Date Updated -30/09/2002

Atmospheric Pressure Sensor - Remove and Install

SMCS - 1923-010

Removal Procedure NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00621509 Typical example

1. Disconnect the harness assembly for atmospheric pressure sensor (1).

2. Remove atmospheric pressure sensor (1).

i01810472

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

Typical example

g00621509

1. Install atmospheric pressure sensor (1). Tighten the sensor to a torque of 10 ± 2 N·m (90 ± 20 lb in).

2. Connect the harness assembly for atmospheric pressure sensor (1).

Product: CHALLENGER

Model: MT865 CHALLENGER BDS

Configuration: C-12, C-15, C-16 Caterpillar Engines For AGCO Challenger BDS00001-UP (MACHINE)

Disassembly and Assembly

C-15 and C-16 Industrial Engines Media

Camshaft - Install

1210-012

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (K) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.

i02963221

Illustration 1

g00509797

Illustration 2

g00581441

2. Install Tooling (A) on the cylinder head at Location (Y).

Illustration 3

g01024862

3. Install Tooling (B) on front housing (7). Do not tighten the bolts that hold Tooling (B) to front housing (7) at this time.

4. Use Tooling (H) to align Tooling (B) with the camshaft bearings. Tighten the bolts that hold Tooling (B) to front housing (7). Remove Tooling (H).

Note: Tooling (H) should move freely from the bore of Tooling (B).

5. Install Tooling (C) in the end of camshaft (8).

Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in the camshaft bearings.

6. Use a suitable lifting device in order to position camshaft (8) into Tooling (B) and the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

Illustration 4

g00581445

Illustration 5

g00581444

Illustration 6

g00581443

Note: Tooling (C) must be removed before the camshaft can be completely installed in the cylinder head.

7. Remove the lifting device. Rotate the camshaft during installation. Use care not to allow the end of the camshaft and Tooling (C) to drop. Use Tooling (D) to assist in aligning camshaft (8) with the camshaft bearings.

8. Remove Tooling (C) and finish installing camshaft (8) in the bore.

9. Remove Tooling (A) and Tooling (B).

Illustration 7

Illustration 8

10. Install O-ring seals (5) and (6) in seal assembly (3). Lubricate seal (6) with Tooling (K).

11. Install seal assembly (3). Position adapter (4). Ensure that the dowel in adapter (4) engages the hole in the camshaft.

12. Position thrust plate (1). Apply Tooling (J) to bolts (2). Hold thrust plate (1) in position and install bolts (2). Evenly tighten bolts (2) until seal assembly (3) and O-ring seal (5) are seated against the cylinder head.

g00576240

g00576839

Note: Be careful in order to ensure that O-ring seal (5) stays in the groove in seal assembly (3).

End By:

a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install".

b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

Alternative Installation Procedure

Table 2

Required Tools

(1) Part of 177-8003 Engine Tool Group

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (K) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.

9 g01043587

2. Install Tooling (F) on the front of camshaft (9) with Tooling (G).

3. Install Tooling (E).

4. Use two technicians to install the camshaft. Carefully slide camshaft (9) into the cylinder head from the rear of the engine. Keep the camshaft level while the camshaft is being installed in the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

5. Remove Tooling (F).

Illustration 10

g01043589

6. Install Tooling (F) on the end of the camshaft.

7. Use two technicians to install the camshaft. Carefully slide camshaft (9) into the cylinder head from the rear of the engine. Keep the camshaft level while the camshaft is being installed in the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

8. Remove Tooling (F).

Illustration

Illustration 11

g01043575

9. Position cover (8) on the rear of the cylinder head. Install bolts (7).

Illustration 12

g00576240

Illustration 13

g00576839

10. Install O-ring seals (5) and (6) in seal assembly (3). Lubricate seal (6) with Tooling (K).

11. Install seal assembly (3). Position adapter (4). Ensure that the dowel in adapter (4) engages the hole in the camshaft.

12. Position thrust plate (1). Apply Tooling (J) to bolts (2). Hold thrust plate (1) in position and install bolts (2). Evenly tighten bolts (2) until seal assembly (3) and O-ring seal (5) are seated against the cylinder head.

Note: Be careful in order to ensure that O-ring seal (5) stays in the groove in seal assembly (3).

End By:

a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install".

b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

Mon Feb 19 23:30:00 UTC+0530 2024

Product: CHALLENGER

Model: MT865 CHALLENGER BDS

Configuration: C-12, C-15, C-16 Caterpillar Engines For AGCO Challenger BDS00001-UP (MACHINE)

Disassembly and Assembly

C-15 and C-16 Industrial Engines

Media Number -RENR2346-01

Camshaft - Remove SMCS - 1210-011

Removal Procedure Table 1

Start By:

a. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

b. Remove the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Remove".

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

i02110801

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE

Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.

1. Remove bolts (2) and thrust plate (1).

Illustration 1

g01028806

Illustration 2

g00576209

2. Remove seal assembly (3) and adapter (4).

Illustration 3

g00576240

3. Remove O-ring seals (5) and (6) from seal assembly (3).

NOTICE

Care must be used when removing the camshaft to not damage the highly finshed surfaces of both the camshaft and camshaft bearings